High speed manipulation of non-uniform objects

ABSTRACT

System and methods for manipulating and sorting of objects being moved along a conveyor are disclosed, whereby control of the object is achieved through the application of one or more of vacuum, impaling, or mechanical grasping. One embodiment is directed to a robotic arm and vision detection system operable for detecting a target object to be grasped from a stream of objects being moved on a conveyor, and moving a suction head into position over the target object that has been detected on the conveyor, the suction head having a flexible cup section disposed at a distal end thereof, the vacuum item pick-up system/method using high subsonic air flow (e.g., on the order of 60 scfm or more) through a suction cup having a flow opening area large enough that an airflow of 60 scfm does not result in an airspeed exceeding Mach 0.2 under standard conditions of temperature and pressure, and further having a flow opening area whose ratio to cup opening area falls between 0.36 and 1.44 for applying a desired vacuum suction force for grasping the target object. Either as a primary grasping mechanism, or as an optional supplemental grasping mechanism, a piercing mechanism may be inserted into the object and used to manipulate the object in space. Alternate systems/methods for manipulating and sorting objects via hitting, flicking, or pushing are also disclosed.

RELATED APPLICATION DATA

This application is a non-provisional of and claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 62/548,817 filed Aug. 22, 2017, the disclosure of which is incorporated by reference herein in its entirety.

BACKGROUND

The field of the present invention relates to a robotic system and robotic end-effector, and more particularly to one capable of high speed manipulation of objects with variable or undefined shape, structure, or size.

In the realm of robotic pick-and-place applications there has been a central focus on performing well-defined, repeatable tasks. This paradigm is fundamentally predictable and specific. Classical computation is adept at processing a precise list of instructions. As a result, technologies have been developed for a narrow range of applications allowing for the interaction with the real world. One such subset is robotic end-effectors for manipulation of objects. An example may be found in food handling applications. Although small variations may exist, the rules for any given operation tend to be very precise and the target object is well-defined. Pick-and-place grasping can be found in numerous industries, but commodity-based grasping is typically designed to leave no trace of handling. Applications exist where destructive methods of grasping can be utilized, one such field is waste handling.

Increases in computation power has led to the expansion of deep learning algorithms. In this paradigm the computer program is much more abstract and the inputs are no longer discrete, such as image recognition. Advancements in this field have numerous industrial applications. One such industry is recycling, the sorting of recycled materials. The nature of recycling is unpredictable with materials varying largely by region and have extreme variations even within that subset. The mechanical component of the robotic system is becoming a limiting factor of these robotic systems. The present inventors have recognized that similar to the shift in software, mechanical technologies need be developed to interact with objects of unpredictable size, shape, orientation, and composition.

SUMMARY

The embodiments described herein are directed to material handling systems, or more specifically, robotic arm sorting systems and methods of sorting, and in one embodiment to a robotic arm sorting system with grasping mechanism/end-effector design capable of reliably manipulating/grasping non-uniform objects. Even objects of indeterminate size, shape, orientation, and surface condition can be grasped and relocated in a given space. This grasping functionality need not be dependent to the specific grasping point chosen by the grasping mechanism. The system may be suitable when miscellaneous objects of indeterminate/varied shape and size are located in the vicinity of the target object and the working environment is not controlled for cleanliness, and/or where the preservation of the object's condition is irrelevant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a vacuum sorting system according to an embodiment, and including a front elevation view of a suction cup embodiment positioned to manipulate a target object.

FIG. 2 is a front isometric view of an example robotic arm and vacuum head section of the sorting system of FIG. 1 according to an embodiment.

FIG. 3 is a top isometric view of the system of FIG. 2.

FIG. 4 is an enlarged isometric view of the vacuum head section of the sorting system of FIGS. 2-3.

FIG. 5 is an isometric view of a suction cup according to an embodiment.

FIG. 6 is a front elevation view of the suction cup of FIG. 5.

FIG. 7 is a cross-sectional view of the suction cup of FIG. 6 taken along line 7-7.

FIG. 8 is a bottom plan view of the suction cup of FIGS. 5-7.

FIG. 9 is an isometric view of a suction cup according to another embodiment.

FIG. 10 is a front elevation view of the suction cup of FIG. 9.

FIG. 11 is a cross-sectional view of the suction cup of FIG. 10 taken along line 11-11.

FIG. 12 is a bottom plan view of the suction cup of FIGS. 9-11.

FIGS. 13-14 are diagrammatic views of an alternate object grasping head according to an embodiment using a piercing mechanism.

FIG. 15 is a diagrammatic view of an alternate object grasping head according to an embodiment using a combination suction head and piercing mechanism.

FIG. 16 is a diagrammatic front view of an alternate object grasping head including a mechanical grasping prong, the prongs being in the open, non-grasping position.

FIG. 17 is a diagrammatic front view of the grasping head of FIG. 16 with the prongs being in the closed, grasping position.

FIG. 18 is a diagrammatic top view of the grasping head of FIG. 17.

FIG. 19 is a diagrammatic front view of an alternate object grasping head including a combination suction head with mechanical grasping prongs of FIGS. 16-18.

FIGS. 20A, 20B, 20C illustrate another alternate system for manipulating objects.

FIGS. 21A, 21B, 21C illustrate another alternate system for manipulating objects.

FIG. 22A is a front elevation view of an alternate suction cup having a suction cup lip formed with radial sections fitted with pressurized veins, the radial sections shown in a first position.

FIG. 22B is a front elevation view of the suction cup of FIG. 22A with the radial sections shown in a second position.

DETAILED DESCRIPTION

Certain embodiments will now be described with reference to the drawings. To facilitate description, any element numeral representing an element in one figure will represent the same element in any other figure. It is noted that embodiments of the grabbing/end-effector mechanisms will be described with reference to a particular robotic arm system, but it will be appreciated that details of the described mechanisms may be applied in other any robotic arm systems or the like.

FIG. 1 is a schematic of a pneumatically-powered vacuum sorting system 10 according to a first embodiment with FIGS. 2-3 being isometric views of the system of FIG. 1 integrated into a robotic arm system. The system 10 is shown as in FIGS. 2-3 to comprise a robotic arm system including a controller 70, an item detection device/system 71 (e.g., a vision system or means for detecting) to see/detect the materials being transferred along the conveyor 5, and artificial intelligence system to think and identify target objects to be sorted. The robotic arm system comprises a plurality of pairs of robotic arms 74, 76 and 72, 73, and 78, 79. Via the robotic arms 74, 76 and 72, 73, and 78, 79, the controller 70 is operative to move and position the suction head 50 in three dimensions to seek out and engage a selected target object, such as a plastic bottle 120 from a stream of objects being conveyed through a target zone via a conveyor 5.

The system 10 may be described as a vacuum pick-up apparatus that includes a specially designed grasping mechanism/end effector, shown as a flexible suction cup unit 100 disposed on the distal end of a tube or pipe section 60 at the bottom of the suction head 50. The suction cup unit 100 is specially designed to provide a high vacuum air flow capacity as will be described further below.

The system 10 is provided with high air flow vacuum pump system (comprising the means to applying a high subsonic vacuum air flow). To meet a desired high vacuum air flow, the system 10 may be constructed with a dual vacuum pump system comprised of a first vacuum pump 12 and a second vacuum pump 32 disposed in parallel. The first vacuum pump 12 is connected via a first flexible hose 18 drawing air through the flexible hose 18 and through a filter 16 and exhausting out through exhaust 14. The flexible hose 18 is connected via a hose barb 19 to a rigid hose 20 which in turn is connected via a second hose barb 21 to a second flexible hose section 22. The second flexible hose section 22 is then connected to vacuum connector/port 54 of the wye connector 52.

Similarly, on the other side, the second vacuum pump 32 is connected via a second flexible hose 38 drawing air through the second flexible hose 38 and through a filter 36 and exhausting out through exhaust 34. The second flexible hose 38 is connected via a hose barb 39 to a rigid hose 40 which in turn is connected via a second hose barb 41 to a second flexible hose section 42. The second flexible hose section 42 is then connected to vacuum connector/port 56 of the wye connector 52.

The wye connector 52 is a multi-port connector/manifold which is shown in FIG. 4 as having the two vacuum line connectors/ports 54, 56 and a blower connector/port 57. The connectors 54, 56 and 57 (collectively comprising a multi-port distribution manifold) all provide for an open fluid connection for air flow through suction head 50 to the lower pipe section 60. The suction cup unit 100 is connected to the end of the lower pipe section 60 via a threaded fitting or connector 102 attached to the top section of the suction cup unit 100. The blower connector 57 is connected via a flexible hose 58 to a pressure source 59 such as an air blower or compressed air source. The pressure source 59, flexible hose 58 and blower connector/port 57 are optional components, but may provide for enhanced releasing force for the object being grabbed.

Alternately, the vacuum air flow may be provided by a single vacuum pump, three (or more) vacuum pumps, or another suitable vacuum source or sources. It is noted that a vacuum pump may comprise any suitable device that draws a vacuum, such as a positive displacement vacuum pump, liquid ring vacuum pump, momentum transfer vacuum pump, regenerative vacuum pump, a venturi vacuum pump, or other.

Following is an example method of grasping items, comprising the steps of:

-   -   detecting, via a vision recognition system, a target object to         be grasped from a stream of objects being moved on a conveyor.     -   using the robotic arms 72-79 of the system 10 to position the         suction head 50 (and the suction cup unit 100) over or onto an         object 120 identified by the vision recognition system to be         sorted.     -   activating the vacuum pressure (vacuum pumps 12, 32) to apply a         vacuum lifting force into the suction cup unit 100 for grasping         the object 120.     -   using the robotic arms 72-79 to lift the object 120 and move it         over a bin or desired sorting location.     -   discontinuing the vacuum pressure (and thus deactivating the         lifting force) being applied and dropping/depositing the object         120 into the bin or other desired sorting location.     -   optionally applying positive pressure (by the pressure source         59) through the suction cup unit 100 to assist in releasing the         object 120. The positive pressure provides a positive releasing         force on the object 120. When the vacuum force is being applied         by the vacuum pumps 12, 32, the pressure source 59 is         disconnected/isolated, to allow the vacuum grasping force to be         applied through the suction cup unit 100.

As described below, in one embodiment, the vacuum pump system is operable for applying a high vacuum flow rate of at least 60 scfm (standard cubic feet per minute) through the suction cup unit 100 of the suction head 50 when the pick-up apparatus is free from grasping a target object (i.e., no item is being grasped by the suction cup unit 100).

FIGS. 5-8 illustrate details of an example suction cup unit 100 according to a first embodiment. The suction cup unit 100 is comprised of a flexible cup section 105 and a connector (inlet section) 102. The connector 102 includes internal female threads 103 (NPT) for connecting to a male-threaded end of the lower pipe section 60 (of FIGS. 1-4). A flexible suction cup 105 is attached to the bottom portion of the connector 102. The example flexible cup section 105 is formed with multiple bellows sections, with the example in FIGS. 5-8 having a first bellow 105 a and a second bellow 105 b and a suction cup lower lip 105 c. Alternatively the flexible suction cup section 105 may be formed with a different number of bellows such as a single bellow, or three or four bellows, or more bellows.

A cup screen element 110 is optionally provided and disposed within the flexible cup section 105, as shown in FIG. 7 disposed in the second bellow 105 b. The screen 110 may be alternatively disposed in another suitable location.

The screen 110, which may be replaceable, may be integrated into the flexible cup section 105. The screen 110 is sized for the screening of materials of a desired size that are small enough or pliable enough to be suctioned into an inner chamber 107 of the flexible cup section 105, but are of such a size (or type, e.g., pliable) that would obstruct the vacuum system. The design of the screen 110 (e.g., the size of the hexagonal openings) is such as to maintain adequate (high) vacuum air flow and not become clogged by dirt and debris while promoting the full grasping functionality. Likewise, miscellaneous smaller items of certain size that are not targeted, but are in the target area, are screened by the screen 110 such that the flexible cup section 105 and any subsequent vacuum hoses 18, 38 do not become clogged with foreign objects, while particles of a given small size (that will not obstruct the vacuum system) are allowed to pass through the screen opening without clogging the screen 110 itself. The screen is sized to have openings large enough to avoid disrupting the high vacuum flow rate but small enough to screen undesirably large (or alternately pliable) items from passing through the suction head. The optional pressure source 59 may optionally assist in removing miscellaneous items trapped by the screen 110, blowing those items back out of the suction cup unit 100.

The optional foam lip unit 112 (of FIGS. 5-8) may be constructed of a suitable flexible (e.g., polymer) material such as open cell foam (e.g., polyurethane open cell foam). The foam lip unit 112 is shown formed as a cylindrical, donut-shaped form having (as shown in FIG. 8) an internal opening of a diameter F and an outer diameter G. The foam lip unit 112 is attached to the bottom of the flexible cup section 105 (i.e., to the lower cup lip 105 c) via an adhesive or other suitable attachment mechanism. The optional foam lip adhesive (or other attachment mechanism) may be selected to allow for the foam lip to be removably attachable (i.e., replaceable), thereby being replaced easily without damaging or replacing the cup section.

The dual vacuum pumps 12, 32 connected to respective vacuum connectors 54, 56 combine to provide for a desired high vacuum air flow through lower pipe section 60 and the inner chamber 107 of the flexible cup section 105.

FIGS. 9-12 illustrate an alternative suction cup unit 200 according to a second embodiment comprised of a flexible cup section 205 and an inlet/connector 202. The connector 202 includes internal female threads 203 (NPT) for connecting to a corresponding male threaded end of the pipe section 60 (of FIGS. 1-4). The flexible cup section 205 attaches to the bottom portion of the connector 202. The flexible cup section 205 is similar to the prior embodiment of the flexible cup section 105 and includes two bellows 205 a and 205 b and a lower lip 205 c. Unlike the prior embodiment, suction cup unit 200 is illustrated without the optional foam lip element whereby contact with the object 120 (shown as a plastic bottle) is made directly by the lower lip 205 c. A high flow screen 210 is shown integrated within an internal chamber 207 of the lower bellow 205 b the screen operating as described in the previous embodiment.

The flexible cup sections 105, 205 may be made of a suitable flexible material such as a flexible polymer material, e.g. polyurethane, or combinations thereof.

The design of the suction cup units may be directed to vacuum handling, that is, to create a low pressure to generate lift and holding force. In an example scenario with the suction cup positioned above the object, this lifting and holding force is accomplished by creating contact with the object and evacuating the air from above the contact area of the object. In order to achieve the vacuum, more air should be evacuated through the suction cup than is leaked through the area of contact. The design of certain embodiments described herein may function by optimizing these two aspects.

First, sealing the object and minimizing leaks into the vacuum chamber is fundamentally achieved by promoting maximum compliance of the suction cup to the surface of the object. The suction cup may be configured to be pressed against the target item without requirement of preserving the condition of the item. A multi-bellow design may allow the flexible cup section to articulate and align to non-orthogonal surfaces. In suction cup unit 200, the soft lip 205 c that forms the base of suction cup unit 200 is flexible so that it can conform to ridges on the object 120. Alternately, the optional foam unit 112 (shown attached to the bottom of the suction cup unit 100 of FIGS. 5-8) may be used at the point of contact to close off the smaller air gaps resulting from more subtle and complex variations in the surface of the object 120 (e.g., a plastic bottle) being grasped. Similarly, without the optional foam unit 112, the soft lip 105 c (of the suction cup unit 100) is flexible so that it can conform to ridges on the object 120.

Second, the bore of the suction cup unit 100,200 is optimized to allow adequate (high) vacuum air flow. This high vacuum air flow capacity of the suction cup is provided to generate sufficient lift force when targeting objects with highly irregular surfaces, even porous surfaces or those containing hole(s) can be grasped. The high vacuum air flow also increases the rate of vacuum creation, which increases the speed in which an object is grasped.

The relative size of the flow opening area (determined by diameter A,A₁ inlet flow opening 106,206) versus the area of the cup opening (determined by diameter D,D₁ of flexible cup section internal opening 107,207) may be designed to maximize the lifting force for the application of grasping items of different/indeterminate size and shape. Suction/lifting force is a function of two variables: area and pressure. If the suction cup opening area (determined by diameter D,D₁) is too large, air may not be evacuated fast enough to create the pressure differential needed to produce adequate lifting force. If the suction cup lip area is too small, a large enough lifting force might not be applied for larger/heavier object no matter what the pressure differential. As described herein, the suction cup opening area refers to the area determined by the inner diameter D,D₁ of the flexible cup section 105,205.

The suction cups employing smaller openings attempt to be as efficient as possible (i.e., lowest power consumption) and employ smaller flow openings (on the order of ½ inch or smaller) according to a lower flow rate (about 10 scfm, or at most 40 scfm) (scfm=standard cubic feet per minute) and thus can only efficiently/consistently pick up smooth surface objects. Further, the flow rate through the smaller cup opening is limited, that is, the smaller ½ inch opening suction cup cannot achieve a higher flow rate, no matter the vacuum pressure applied, due to limitations allowed by air speed from subsonic to supersonic as choked flow ensues.

In contrast to other systems employing smaller openings and lower flow rates, certain embodiments described herein may provide a higher desired flow rate, e.g., a high subsonic vacuum air flow rate of at least 60 scfm, or in a range of 60 scfm to 120 scfm, during free flow when the pick-up apparatus is free from grasping a target object (i.e., no item is being grasped by the suction cup 100,200) which is achievable through the larger flow opening area (determined by A,A₁) and with a ratio of inlet flow opening area to flexible cup section opening area (ND; A₁/D₁) of at least 0.46, or between 0.36 and 1.44, or between 0.46 and 1.15. Further, in one example, the flow opening area is such that the minimum flow rate (60 scfm) does not produce a ratio of volumetric flow rate to area which exceeds Mach 0.2, under standard conditions for temperature and pressure.

As noted, in order to create a lower pressure, more air should be evacuated than is leaked into the cavity of the suction cup. Supplemental methods/systems for closing off the gaps responsible for air leakage are envisioned. FIGS. 22A-B illustrate an embodiment of such a method/system comprising an alternate suction cup unit 700 is comprised of a flexible cup section 705 and a connector (inlet section) 702 similar to the prior described embodiments. The suction cup unit 700 includes a suction cup lip 710 that is formed with a plurality of radial segments 720 that are fitted with veins 715 that, when filled with pressurized air, cause elongation of a corrugated top surface while the structure of the lower surface resists elongation. As a result, there is a moment force (bending moment) that will control concavity of the flexible lip section and force the lip of the suction cup to conform more closely to the irregular surfaces of the target object.

FIG. 22A illustrates the veins 715 in the non-pressurized state whereby the radial segments 720 are arranged in a first position with a relatively flat concavity. FIG. 22B illustrates the veins in a pressurized state applying the bending moment to move the radial segments into second position of a greater concavity. This design may be operable to further close off air gaps and increase the lifting force generated by a given vacuum source, allowing better suction cup performance on a wider range of irregularly-shaped target objects.

Table A below provides vacuum pump data for an example vacuum pump suitable for use in the present system, the pump being a model piClassic available from Piab USA, Inc. of Hingham, Mass.

TABLE A Vacuum Pump Vac Pump piClassic Cartridges si32-3 x 6 V-Flow, inHG Vacuum Flow SCFM 0 61.00 3 37.90 6 31.40 9 21.60 12 11.40 15 7.63 22.1 0

The vacuum pump may provide a relatively high vacuum level such as at least 16 inHG at zero air flow. To further accommodate the higher air flow rate, in an embodiment, the supply lines 18-22, 38-42 and 60 also have large (internal) diameter.

As a supplement (i.e., in conjunction with) or stand-alone, the grasping mechanism may comprise a mechanical device that pierces target objects to control and manipulate them. One such application of this design includes three primary features; a pointed flute/spike, an object contactor, and a ridged work surface. FIGS. 13-14 are diagrammatic views of an alternate object grasping mechanism according to an embodiment using a piercing mechanism and part stop (object contactor). As shown in FIG. 13, a target object 320, shown as for example a plastic bottle, is pinned between a weighted part stop 310 and a conveyor 315 (or optionally ridged work surface). In this state, movement (e.g., axial rotation) of the object 320 is constrained allowing a flute/spike 302 to penetrate the object 320. The flute 302 embeds in such a way that little or no material is removed from the object 320 and once inserted frictional forces allow manipulation of the object 320.

In one embodiment, the flute 302 includes a proximal end 304 attached to a drive/support mechanism of a robotic arm (as in a prior embodiment), a pointed distal end 308 for piercing the object 320, and a knurled or threaded end section 306 extending from the center to the pointed distal end 308. While the object 320 is pinned against the work surface 315, the flute 302 may be inserted into the object 320, the pointed distal end 308 piercing the wall of the object. The end section 306 may optionally comprise a spiral thread or threaded knurl section, and the flute 302 may then be axially rotated (in a first direction) during insertion into the object 320. Once inserted, the end section 306 provides a friction connection enabling the object to be lifted off the work surface 315 (and held against the part stop 310) and manipulated to a desired position for ejection. To eject or deposit the object 320, as shown in FIG. 14, the flute 302 is retracted into the part stop 310 whereby the object 320 falls by gravity into a sorting bin or other location. Optionally, the flute 302 may be counter-rotated (axially rotated in a second/opposite direction) during retraction in the embodiment where the flute 302 includes a spiral (e.g., a high pitch helix thread) or threaded knurl. FIG. 14 shows the process for releasing the object, where the part stop 310 applies a force to the object 320 and the (threaded) flute 302 reverses rotation and draws out of the object, thereby releasing the impaled object 320.

FIG. 15 is a diagrammatic view of an alternate grasping mechanism 400 of a combination mechanical piercing mechanism (or impaling device) 402 (similar to the piercing mechanism 302 as in FIGS. 13-14) and (high flow) suction cup 410 (similar to the suction cup 100 as in FIGS. 5-8 or the suction cup unit 200 as in FIGS. 9-12). FIG. 15 shows the piercing mechanism 402 paired with a high flow suction cup 410, in this embodiment, the piercing mechanism (shown as a pierced spike) 404 includes a proximate end section 404, a knurled or spiral flute insertion section 406 and a pointed distal end 408. The pierced spike 404 supplements the holding force of the vacuum applied by the suction cup 410 and adds shear resistance (via the knurled/spiral flute insertion section 406) to the object 320 which may allow for higher acceleration and faster transport of the object 320 from the conveyor 315.

FIGS. 16-18 illustrate a system of manipulating an object or group of objects with the use of a finger-like/arm mechanism 500 actuating/pivoting in swinging manner to pinch, pierce and/or cradle the object. The arm mechanism 500 includes three arm units 520, 530, 540 arranged/spaced at 120° around the cup mechanism 510. The first arm unit 520 includes a first arm section 522 and a second arm section 524, a first elbow/hinge 526 for allowing articulation/pivoting between the first arm section 522 and the support plate 519, and a second elbow 528 (optionally a hinge allowing articulation/pivoting) connecting the first arm section 522 and the second arm section 524. The second arm section 524 is shown having a pointed distal end 525 for allowing a point or piercing contact with the object. The second arm unit 530 includes a first arm section 532 and a second arm section 534, a first elbow/hinge 536 for allowing articulation/pivoting between the first arm section 532 and the support plate 519, and a second elbow 538 (optionally a hinge for allowing articulation/pivoting) connecting the first arm section 532 and the second arm section 534. The second arm section 534 is shown having a pointed distal end 535 for allowing a point or piercing contact with the object. The third arm unit 540 includes a first arm section 542 and a second arm section 544, a first elbow/hinge 546 for allowing articulation/pivoting between the first arm section 542 and the support plate 519, and a second elbow 548 (optionally a hinge for allowing articulation/pivoting) connecting the first arm section 542 and the second arm section 544. The second arm section 544 is shown having a pointed distal end 545 for allowing a point or piercing contact with the object. The arm units 520, 530, 540 are arranged and separated at 120° from each other so as to grasp the object in a suitable pinching motion. Releasing the object is achieved by forcing/moving the arms back to the open position. Grasping and handling of the object may be done without regard for the preservation of the target object.

FIG. 19 depicts a combination system 500A including both the arm mechanism 500 (of FIGS. 16-18) paired with a high flow vacuum cup mechanism 510 with an internal screen 514 (such as the cup mechanisms described in certain prior embodiments).

FIGS. 20A-C illustrate a mechanism 600 for relocating or manipulating objects (such as target object 615) in a given space by means of impact, flipping, or nudging the target object, or group of objects being moved along a conveyor 605. This object relocation is achieved without the need for directly grasping the object. FIGS. 20A-C show one such embodiment operating via a precisely directed high-speed impact of a moving/impacting element 610 onto the target object 615, thus generating sufficient kinetic energy to displace the target object from its original position to a new desired location. A similar method is envisioned as a second application, by contacting the object at a synchronous speed and accelerating in such a manner to flip the target object to a new location.

FIGS. 21A-C illustrate another embodiment for manipulating objects comprising a system/method for nudging a moving target object 665 off its current trajectory (being moved along via a conveyor 655), resulting in a two dimensional displacement of the object 665. This nudging may be achieved using a stationary or relatively slow-moving rigid body 660 to deflect the moving target object 665 off its current trajectory, relocating it in space. This methodology may be applied to the object 665 more than once, or until the desired final position is satisfied. This process of multiple, slight (incremental) deflections may provide a cumulative effect of segregating desired materials from their original co-mingled stream of miscellaneous objects.

Other embodiments are envisioned. Although the description above contains certain specific details, these details should not be construed as limiting the scope of the invention, but as merely providing illustrations of some embodiments/examples. It should be understood that subject matter disclosed in one portion herein can be combined with the subject matter of one or more of other portions herein as long as such combinations are not mutually exclusive or inoperable.

The terms and descriptions used herein are set forth by way of illustration only and not meant as limitations. It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the inventions. 

1. A vacuum pick-up apparatus usable in a material handling system for grasping a target object, comprising: a vacuum pump system operable to apply a vacuum air flow; a suction head coupled to and receiving vacuum air flow from the vacuum pump system, the suction head comprising a suction cup unit having (a) an inlet section with an inlet flow opening area capable of flowing 60 scfm (standard cubic feet per minute) without an airspeed exceeding Mach 0.2 under standard conditions for temperature and pressure, and (b) a flexible suction cup section having an inner open area such that the ratio of the inlet flow open area to inner cup opening area is between 0.36 and 1.44, wherein the vacuum pump system is operable to apply a desired vacuum air flow of at least 60 scfm through the suction cup unit of the suction head when the apparatus is free from grasping a target object.
 2. A vacuum pick-up apparatus according to claim 1 wherein the ratio of the inlet flow open area to inner cup opening area is between 0.46 and 1.15.
 3. A vacuum pick-up apparatus according to claim 1 wherein the vacuum pump system comprises a first vacuum pump connected via a first flexible hose to the suction head and a second vacuum pump connected via a second flexible hose to the suction head, the first and second vacuum pumps combining to provide the desired vacuum air flow through the suction cup unit.
 4. A vacuum pick-up apparatus according to claim 3 wherein the suction head further comprises a multi-port manifold including a first port connected to the first flexible hose and a second port connected to the second flexible hose.
 5. A vacuum pick-up apparatus according to claim 4 comprising an air pressure source, wherein the suction cup unit is operable to grasp a target object via application of the desired vacuum air flow through the suction cup unit, wherein the multi-port manifold includes a third port connected to the air pressure source, wherein the air pressure source is operable to apply a positive air pressure into the suction head to assist in cleaning the vacuum system and releasing the target object from the suction cup unit.
 6. A vacuum pick-up apparatus according to claim 1 where a force is applied, in addition to gravity, to assist in releasing the target object from the suction cup unit.
 7. A vacuum pick-up apparatus according to claim 1 wherein the flexible cup section comprises (a) a multiple bellows construction including at least first and second bellows, (b) a screen element disposed within one of the bellows, the screen element having openings large enough to avoid disrupting the desired vacuum air flow but small enough to screen items from passing through the flexible cup section.
 8. A vacuum pick-up apparatus according to claim 1 wherein the suction cup unit comprises a foam lip unit disposed on a distal end of the flexible cup section, the foam lip unit having a cylindrical, donut-shaped form.
 9. A vacuum pick-up apparatus according to claim 8 wherein the foam lip unit is removably attachable to the distal end of the flexible cup section.
 10. A vacuum pick-up apparatus according to claim 9 wherein the foam lip unit is adhered to the flexible cup section using an adhesive that allows the foam lip to be replaced without damaging or removing the flexible cup section.
 11. A vacuum pick-up apparatus according to claim 8 wherein the foam lip unit is constructed from a polyurethane open cell foam material.
 12. A vacuum pick-up apparatus according to claim 1 wherein the flexible cup section is constructed from a flexible polymer material.
 13. A vacuum pick-up apparatus according to claim 1 wherein the flexible suction cup section includes a flexible lip section at a distal end thereof, wherein the flexible lip section is formed with a plurality of radial segments, wherein concavity of the flexible lip is actively controlled by applying a moment force to any number of the radial segments.
 14. A vacuum pick-up apparatus according to claim 1 further comprising a detection system operative for detecting a target object to be grasped and sorted from a stream of non-uniform objects being moved via a conveyor; a robotic arm operative (a) to move the suction head into position over or onto the target object to engage the suction cup unit onto the target object to grasp the target object, and (b) once the target object is grasped by vacuum force applied via the suction cup unit, to move the suction head with the grasped target object to a desired location for depositing the target object.
 15. A method for manipulating and sorting of non-uniform objects being moved on a conveyor, comprising via a robotic arm, moving a suction head into position over the target object, the suction head having a flexible suction cup disposed at a distal end thereof; applying a high subsonic vacuum air flow on the order of at least 60 scfm (standard cubic feet per minute) through the suction head and through the flexible suction cup when the target object is not being grasped; via the robotic arm, moving the suction head to position the flexible suction cup over or onto the target object and grasping the target object via the vacuum air flow; via the robotic arm, moving the target object that has been grasped to a desired location; depositing the target object in the desired location by discontinuing the vacuum air flow to the flexible suction cup.
 16. A method according to claim 15 wherein applying a high subsonic vacuum air flow comprises connecting a first vacuum pump via a first flexible hose to the suction head, connecting a second vacuum pump via a second flexible hose to the suction head, combining flows from the first and second vacuum pumps to provide the high vacuum air flow through the flexible suction cup.
 17. A method according to claim 15 further comprising providing the flexible suction cup with (a) an inlet section with an inlet flow opening area capable of flowing 60 scfm without an airspeed exceeding Mach 0.2 under standard conditions for temperature and pressure, and (b) a flexible suction cup section having an inner open area such that the ratio of the inlet flow open area to inner cup opening area is between 0.36 and 1.44.
 18. A method according to claim 15 further comprising providing the flexible suction cup with (a) an inlet section with an inlet flow opening area capable of flowing 60 scfm without an airspeed exceeding Mach 0.2 under standard conditions for temperature and pressure, and (b) a flexible suction cup section having an inner open area such that the ratio of the inlet flow open area to inner cup opening area is between 0.46 and 1.15.
 19. A method according to claim 15 wherein the step of applying a high subsonic vacuum air flow comprises connecting a first vacuum pump via a first flexible hose to the suction head, connecting a second vacuum pump via a second flexible hose to the suction head, combining vacuum air flows from the first and second vacuum pumps to provide the high vacuum air flow through the flexible suction cup.
 20. A method according to claim 15 wherein depositing the target object comprises positively releasing the target object by applying a positive pressure to the flexible suction cup from a pressure source along with discontinuing the vacuum air flow to the flexible suction cup.
 21. A method according to claim 15 further comprising detecting a target object to be grasped from a stream of objects being moved on a conveyor.
 22. A system for manipulating and sorting of non-uniform objects being moved on a conveyor, comprising means for detecting a target object to be grasped from a stream of objects being moved on a conveyor; a robotic arm operative to move a suction head into position over the target object that has been detected on the conveyor, the suction head having a flexible suction cup disposed at a distal end thereof; means for applying a high subsonic vacuum air flow on the order of at least 60 scfm (standard cubic feet per minute) through the suction head and through the flexible suction cup when the system is free from grasping a target object; wherein the robotic arm is operative to move the suction head to place the flexible suction cup onto the target object, whereby the flexible suction cup is operative to grasp the target object via the vacuum air flow; wherein the robotic arm is operative to move the target object that has been grasped to a desired location; means for depositing the target object in the desired location by discontinuing the vacuum air flow to the flexible suction cup.
 23. A vacuum pick-up apparatus usable in a material handling system for manipulating an object, comprising: a suction head comprising a flexible suction cup having an inlet flow opening; a vacuum pump system operable for applying a vacuum flow rate through the flexible suction cup of the suction head and manipulating an object; a mechanical piercing mechanism operable for moving in conjunction with the flexible suction cup and piercing into the object to assist in manipulating the object.
 24. An apparatus usable in a material handling system for manipulating an object, comprising: mechanical piercing mechanism comprising a tapered body with a helical flute and a weighted member; wherein the mechanical piercing mechanism rotatable around its axis; wherein the mechanical piercing mechanism is axially movable, relative to a target object for piercing into the target object; wherein the weighted member is axially movable, relative to the piercing mechanism.
 25. An apparatus according to claim 24 wherein the mechanical piercing mechanism is axially rotatable in a first direction when it is piercing into the object for manipulating and axially rotatable in a second opposite direction for releasing the object.
 26. An apparatus according to claim 24, wherein the weighted member is operable to stabilize and restrain the target object during manipulation.
 27. An apparatus according to claim 26, wherein the weighted member is operable to oppose movement of the target object during release.
 28. An apparatus usable in a material handling system for manipulating an object, comprising: mechanical piercing mechanism comprising a plurality of pivoting arms having pointed ends, the pivoting arms being pivoted to manipulate a target object via the pointed ends piercing into the target object.
 29. An apparatus according to claim 28, wherein one or more of the arms pierces the target object.
 30. An apparatus according to claim 29, wherein one or more of the arms stabilizes the target object that has been pierced.
 31. A system for manipulating and sorting of non-uniform objects being moved on a conveyor, comprising: a mechanism for striking a target object and using kinetic energy to manipulate the target object in space; or a mechanism for contacting and precisely accelerating a target object through three dimensions and manipulating the target object in space; or a mechanism for contacting and deflecting a moving object slightly off its current trajectory onto a new trajectory and manipulate such that it is separated from its neighbor items for subsequent sorting. 